Anvil with curved passage for cutting tool

ABSTRACT

An anvil for a cutting tool includes an anvil body. A curved passage extends from an inlet opening in the anvil body to an outlet opening in the anvil body. The anvil body can be made by an additive manufacturing process.

BACKGROUND AND SUMMARY

The present invention relates generally to anvils for cutting tools and,more particularly, to such anvils having fluid passages therein.

Cutting tools for modern metal cutting and other machining operationstypically include toolholders with replaceable cutting inserts. Thecutting inserts are typically made of much harder materials, such assintered, cemented carbide, than the toolholders. The cutting insertsare typically clamped in recesses provided in the toolholders for thecutting inserts. Often, an anvil (sometimes referred to as a shim) isprovided in the recess between the bottom surface of the recess and thebottom surface of the cutting insert. One purpose for providing an anvilis to position the cutting edge(s) of the cutting insert relative to thetoolholder in a desired fashion.

Because of high temperatures generated during cutting operations, it isoften desirable to provide cooling and/or lubricating fluid near thecutting edge of the cutting insert. It is also often desirable toprovide fluid for removing of chips generated at the workpiece by thecutting operation. One technique for providing fluid for cooling,lubricating, and/or flushing is to position a nozzle above the cuttingedge so that fluid can be directed at the cutting edge. This arrangementis disadvantageous in that it requires additional equipment and isdifficult to use in applications involving small tools or workpieces. Itis also largely limited to turning applications where the tool is notrotating, and is difficult or impossible to use in applications such asmilling operations.

Another technique for providing fluid for cooling, lubricating, and/orflushing is to direct fluid through passages in the toolholder and, insome instances, through passages in the cutting insert. EP2946857A1shows a turning tool holder and cutting insert with an anvil having apassage extending therethrough for introducing fluid to the cuttingedge.

It is desirable to provide an anvil for a cutting tool with a passagehaving a complex geometry to facilitate providing fluid through theanvil. It is also desirable to be able to produce such an anvil by asimple, accurate technique.

According to an aspect of the present invention, an anvil for a cuttingtool comprises an anvil body, wherein a curved passage extends from aninlet opening in the anvil body to an outlet opening in the anvil body.

A curved passage in an anvil provides options for providing fluid tocool and/or lubricate a cutting insert, and/or flush chips away from aworkpiece that are not possible or are only possible via passages in theanvil having complex geometries when passages extend along straightlines. The anvil provides additional geometry options for providing acoolant/lubrication/flushing beam from below a cutting insert withoutadvanced drilling or blind plugging operations.

The anvil itself is applicable to most cutting insert clamping systems.The anvil can be manufactured at different thicknesses, depending onwhat is most suitable for the cutting insert shape. The anvil can, ifdesired, extend fully through the cutting toolholder to the bottomsurface of the toolholder.

According to another aspect of the invention, the anvil comprises a topsurface, a bottom surface, and a side surface between the top surfaceand the bottom surface, the side surface comprising at least three sidesurface portions and at least three corner portions, each corner portionof the at least three corner portions being disposed between respectivepairs of side surface portions of the at least three side surfaceportions, at least one corner portion of the at least three cornerportions comprising a surface that extends radially outward from acentral axis of the anvil relative to extensions of a respective pair ofside surface portions of the at least three side surface portions, thecentral axis extending between the top surface and the bottom surface.By providing such a structure, a limited portion of the top surface ofthe anvil can extend past a bottom surface of the cutting insert todefine an exposed area and the outlet opening can be provided in theexposed area, facilitating directing fluid toward the cutting edge.

In accordance with yet another aspect of the invention, a method formaking an anvil for a cutting tool comprises forming an anvil bodyhaving a curved passage that extends from an inlet opening in the anvilbody to an outlet opening in the anvil body.

The method provides options for providing fluid to cool and/or lubricatea cutting insert, and/or flush chips away from a workpiece that are notpossible or are only possible via passages in anvils having complexgeometries when passages extend along straight lines. The methodprovides additional geometry options for providing acoolant/lubrication/flushing beam from below a cutting insert withoutadvanced drilling or blind plugging operations.

In accordance with still a further aspect, the anvil body can be formedvia an additive manufacturing process. By forming an anvil via anadditive manufacturing process, an anvil having a complex shape,particularly a complex interior geometry such as including a curvedpassage, can be formed. Moreover, such an anvil can be formed at minimalcost.

In according with yet another aspect, a cutting tool including an anvilas described is provided.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present invention are well understoodby reading the following detailed description in conjunction with thedrawings in which like numerals indicate similar elements and in which:

FIGS. 1-4 are a perspective, a top, a side, and a bottom view of ananvil according to an aspect of the present invention;

FIG. 5 is a perspective view of a cutting tool including an anvilaccording to an aspect of the present invention, and

FIG. 6 is an enlarged view of a portion of FIG. 5;

FIG. 7 is a top view of the cutting tool including an anvil according toan aspect of the present invention, and

FIG. 8 is an enlarged view of a portion of FIG. 7;

FIGS. 9A and 9B are side views of anvils according to further aspects ofthe present invention;

FIG. 10 is a perspective view of an anvil according to another aspect ofthe present invention;

FIG. 11 is a perspective view of an anvil according to yet anotheraspect of the present invention; and

FIGS. 12-14 are a perspective, top, and side view of an anvil accordingto still yet another aspect of the present invention.

DETAILED DESCRIPTION

EP2946857A1, however, only provides a fluid passage through the anvilthat is in a straight line. A passage having a straight line structurelimits options available for providing fluid by the cutting edge. Forexample, in the event that the anvil is secured to the toolholder by abolt or other structure extending through a hole in the anvil, the holemay make it impossible to provide a passage that extends along astraight line. Forming a passage that goes around the hole may requireseveral manufacturing steps such as advanced drilling and/or blindplugging operations, adding to the cost of the cutting insert.

FIGS. 1-4 in the present patent application show an anvil 21 for acutting tool 23 of the type shown in FIGS. 5-8. The cutting tool 23illustrated in FIGS. 5-8 is a turning tool, however, the invention isnot limited to turning tools and may be applicable to other tools thatuse anvils (also referred to as shims), such as rotating tools, such asmilling tools. As seen, for example, in FIG. 5, the cutting tool 23 hasa tool body or toolholder 25 in which a recess 27 is provided. Therecess 27 can include a bottom abutment surface 29, and two sideabutment surfaces 31 and 33. A cutting insert 35 is mounted in therecess 27 on top of the anvil 21. Typically, side supporting surfaces 37and 39 of the cutting insert 35 abut the side abutment surfaces 31 and33 of the recess 27, and a bottom supporting surface 41 of the cuttinginsert abuts a top surface, also referred to as a top abutment surface,43 (FIG. 1) of the anvil 21. Side surfaces, also referred to as sidesupporting surfaces, 45 and 47 of the anvil 21 typically abut the sideabutment surfaces 31 and 33 of the recess, and a bottom surface, alsoreferred to as a bottom supporting surface, 49 (FIG. 4) of the anvilabuts the bottom abutment surface 29 of the recess 27. A clamp 51 isprovided to clamp the cutting insert 35 in the recess 27. The clamp 51may also clamp the anvil 21 in the recess 27. Alternatively, the anvil21 may be clamped in the recess 27 by a clamping arrangement separatefrom the clamp 51 that clamps the cutting insert 35. For example, theanvil 21 may be clamped in the recess 27 by a screw or bolt that extendsthrough a central opening 53 in the anvil while the insert may beclamped by a separate clamp 51, such as the cantilever clamping assemblyshown.

As seen in FIGS. 1-4, the anvil 21 comprises an anvil body 55, and acurved passage 57 extends from an inlet opening 59 in the anvil body toan outlet opening 61 in the anvil body. In the embodiment shown in FIGS.1-4, the curved passage 57 extends from an inlet opening 59 in thebottom surface 49 of the anvil 21 to an outlet opening 61 in the topsurface 43 of the anvil. The expression “curved passage” is expresslydefined herein as referring to passages that are not straight over theirlength and is particularly to be contrasted to a passage made up only ofone straight portion, or more than one connected straight portions.Ordinarily, a “curved passage” will have a mathematically continuouscurvature, however, it may comprise plural discontinuous mathematicallycontinuously curved components as shown in FIGS. 9A and 9B, includingplural curved components 57 a and 57 b that are adjacent to each otherto form a curved passage 571 as shown in FIG. 9A and plural curvedcomponents 57 a′ and 57 b′ that are separated by a straight component 57c′ to form a curved passage 572 as shown in FIG. 9B. A “curved passage”will transit sufficiently smoothly to provide minimal risk for cloggingand/or significant pressure drop. The cross-sectional area of thepassages may change, typically becoming smaller as the passage transitsfrom its inlet opening(s) 59 to its outlet opening(s) 61. The inletopening 59 of the curved passage 57 will typically connect to a passage(not shown) in the toolholder 25 or elsewhere so that fluid can enterthe passage and pass to the outlet opening 61, usually for flushingchips from the cutting edge of the cutting insert 35 and/or for coolingthe cutting edge.

In addition to or instead of having a curved passage that extends froman inlet opening in the bottom surface 49 of the anvil 21′ to an outletopening in the top surface 43 of the anvil, the curved passage 57′ mayextend from an inlet opening 59′ in the side surface 45′ and/or 47′ ofthe anvil as seen in FIG. 10. In addition to or instead of having acurved passage that extends from an inlet opening in the bottom surface49 of the anvil 21″ to an outlet opening in the top surface 43 of theanvil, the curved passage 57″ may extend to an outlet opening 61 a″ or61 b″ in the side surface 75″ and/or 77″ of the anvil as seen in FIG.11. In addition to the anvil 21 having one or more curved passages, theanvil may also include one or more straight passages (not shown).

As seen in FIGS. 1-4, the passage 57 can have at least two branches. Theanvil 21 comprises the central hole 53, the passage 57 comprises pluralbranches 63 and 65, and the inlet opening 59 comprises plural inletopenings 69 and 71, respectively. The first inlet opening 69 of thefirst branch 63 is disposed on a first side of the central hole 53, andthe second inlet opening 71 of the second branch 65 is disposed on asecond side of the central hole opposite from the first branch.

If desired, one or more inlet openings (not shown) may be provided inthe central hole so that fluid can flow through the central hole intothe inlet openings and then through the curved passage.

In the anvil 21′ shown in FIG. 10, the passage 57′ comprises pluralbranches 63′ and 65′, and the inlet opening 59′ comprises plural inletopenings 69′ and 71′. The first inlet opening 69′ of the first branch63′ is disposed in a first side surface 45′ of the anvil, and the secondinlet opening 71′ of the second branch 65′ is disposed in a second sidesurface 47′ of the anvil different from the first side surface.

To illustrate the variety of curved passage configurations possible, inthe anvil 21″ shown in FIG. 11, the passage 57″ comprises pluralbranches 63″, 65″, and 67″, and the inlet opening 59″ comprises pluralinlet openings 69″, 71″, and 73″. The first inlet opening 69″ of thefirst branch 63″ is disposed in the side surface 45″ of the anvil, andthe second inlet opening 71″ of the second branch 65″ is disposed in thebottom surface 49″ of the anvil, and the third inlet opening 73″ of thethird branch 67″ is disposed in the side surface 47″. The outletopenings 61 a″ and 61 b″ are disposed in the side surfaces 75″ and 77″(considering portions of the corner portion 85″ to be part of these sidesurfaces), respectively, however, they might alternatively oradditionally be disposed in the top surface 43″. There may be adifferent number of outlet openings than inlet openings, and there maybe more outlet openings than inlet openings or vice versa. The outletopening(s) will ordinarily be disposed in at least one of the sidesurface and the top surface and the inlet opening(s) will ordinarily bedisposed in at least one of the bottom surface and the side surface,however, an outlet opening might be disposed in the bottom surface andan inlet opening might be disposed in a top surface.

Referring, for purposes of discussion, to FIG. 1, it will be seen thatthe anvil 21 can have plural side surfaces 45 and 47. Typically, ananvil with plural side surfaces will have at least three side surfacesdefined by corners or corner portions, i.e., will be substantiallytriangular, or will have more sides, such as the four sides illustratedin the anvil of FIG. 1. In the anvil 21, there are four straight sidesurfaces 45, 47, 75, and 77 and four corner portions 79, 81, 83, and 85disposed between pairs of the side surface portions. At least one cornerportion 85 of the at least three corner portions comprises a surface 87that extends radially outward from a central axis CA (FIG. 1) of theanvil 21 relative to extensions of the pair of side surface portions 75and 77 separated by the corner portion 85, the central axis extendingbetween the top surface and the bottom surface. By “extensions of thepair of side surface portions 75 and 77” it is intended to refer to thesurfaces that would be defined if the side surface portions 75 and 77were extended beyond where they are shown as ending and the cornerportion 85 starts in FIG. 2, and illustrated by two dashed, straightlines E75 and E77 therein. The dashed, straight lines may intersectwithin the periphery of the anvil. By providing the corner portion 85with the surface portion 87 that extends outwardly in this fashion, aportion of the top surface 43 of the anvil 21 can extend beyond thebottom supporting surface 41 of the cutting insert 35 as shown in FIGS.5-8. The outlet opening 61 can be provided in this portion of the topsurface 43 to facilitate providing cooling/flushing fluid to the cuttingedge above the cover portion 85.

FIGS. 12-14 show an anvil 121 according to another aspect of theinvention in which an intermediate surface 200 is provided on aprotruding corner 185 of the anvil. An outlet opening 161 can beprovided in the intermediate surface 200. Inlet openings (not shown) andother outlet openings (not shown) can be provided in any other surfacesas desired. The intermediate surface 200 is disposed below the topsurface 143 and above the bottom surface 149, although the intermediatesurface may extend to the top surface and/or the bottom surface. Asillustrated, a plane of the intermediate surface 200 is parallel to aplane of the top surface 143 and a plane of the bottom surface 149 (FIG.3), however, the intermediate surface may form a non-zero angle withplanes of the top or bottom surfaces and/or may be curved. Providing anintermediate surface 200 in which an outlet opening 161 can be providedbetween the top and bottom surfaces 143 and 149 and, more particularly,below the top surface, can facilitate providing workpiece clearance whenthe anvil 121 is used with thinner cutting inserts, negative inserts, ortoolholders with small rake and/or inclination angles. The surface 187of the protruding corner 185 may be at the same inclination angle as therest of the side surface(s) of the anvil at a different inclinationangle from some or all of the rest of the side surface(s) of the anvil.

Tool life generally increases with increase in coolant supply pressure.This can be attributed to the ability of the high-pressure coolant tolift the chip and gain access closer to the cutting interface. Thisaction leads to a reduction of the seizure region, thus lowering thefriction coefficient, which in turn results in reduction in cuttingtemperature and cutting forces. Preferably the pressure used in thediscussed embodiments is above 30 bar, and more preferably above 100 barcoolant pressure.

In another aspect of the invention, a method for making an anvil 21 fora cutting tool 23 comprises forming an anvil body 55 having a curvedpassage 57 that extends from an inlet opening 59 in the anvil body to anoutlet opening 61 in the anvil body. The anvil body 55 can be formed viaany suitable one of a plurality of different additive manufacturingprocesses such as metal 3D printing processes that use binders, or fullydense metal processes such as selective laser sintering (SLS) or directmetal laser sintering (DMLS). DMLS technology, for example, uses a highpower laser to fuse small particles of metal powders into a shim oranvil that has a desired three dimensional shape. A laser beam “draws”directly on the powder so that only selected portions of the powder aresolidified. The powder is said to be “scanned” by the laser. The use ofa laser in this manner allows layers of different shape to be easily andrapidly fused, enabling complex objects with intricate internalstructures to be produced. The laser selectively fuses the powderedmetal by scanning the cross-sections (or layers) generated by a threedimensional modeling program on the surface of a powder bed. After eachcross-section is scanned, the powder bed is lowered by one layerthickness. Then a new layer of material is applied on top and theprocess is repeated until the shim is completed. Such a process makes itpossible to produce complex anvils with shapes such as curved passages.Thus, the curved passage exhibits a continuous course, which isoptimized from the point of view of flow engineering and which can beproduced, for example, by means of an additive manufacturing process.Machining subsequent to additive manufacturing may also be performed.

In the present application, the use of terms such as “including” isopen-ended and is intended to have the same meaning as terms such as“comprising” and not preclude the presence of other structure, material,or acts. Similarly, though the use of terms such as “can” or “may” isintended to be open-ended and to reflect that structure, material, oracts are not necessary, the failure to use such terms is not intended toreflect that structure, material, or acts are essential. To the extentthat structure, material, or acts are presently considered to beessential, they are identified as such.

The curved passage is to be distinguished from a groove or a curvedgroove in a surface of the anvil. The curved passage is curved along itslength, and is tubular in that the wall or walls of the curved passageextend entirely around a longitudinal axis of the passage.

While this invention has been illustrated and described in accordancewith a preferred embodiment, it is recognized that variations andchanges may be made therein without departing from the invention as setforth in the claims.

1. An anvil for a cutting tool, the anvil comprising: an anvil bodyhaving a curved passage that extends from an inlet opening in the anvilbody to an outlet opening in the anvil body.
 2. The anvil as set forthin claim 1, the anvil body including a top surface and a bottom surface,wherein the curved passage extends from the inlet opening in the bottomsurface.
 3. The anvil as set forth in claim 1, the anvil body includinga top surface, a bottom surface, and a side surface between the topsurface and the bottom surface, the curved passage extending from theinlet opening in the side surface.
 4. The anvil as set forth in claim 1,the anvil body including a top surface, and a bottom surface, whereinthe curved passage extends to the outlet opening in the top surface. 5.The anvil as set forth in claim 1, the anvil body including a topsurface, a bottom surface, and a side surface between the top surfaceand the bottom surface, wherein the curved passage extends to the outletopening in the side surface.
 6. The anvil as set forth in claim 1,wherein the curved passage has at least two branches.
 7. The anvil asset forth in claim 1, wherein the anvil body including a central hole,the curved passage having a plurality of branches, and the inlet openinghaving a plurality of inlet openings, wherein a first inlet opening of afirst branch of the plurality of branches is disposed on a first side ofthe central hole, and wherein a second inlet opening of a second branchof the plurality of branches is disposed on a second side of the centralhole opposite from the first branch.
 8. The anvil as set forth in claim1, wherein the curved passage has a plurality of branches, and the inletopening has a plurality of inlet openings, wherein a first inlet openingof a first branch of the plurality of branches is disposed in a firstside surface of the anvil, and wherein a second inlet opening of asecond branch of the plurality of branches is disposed in a second sidesurface of the anvil opposite from the first side surface.
 9. The anvilas set forth in claim 1, wherein the curved passage has a plurality ofbranches, and the inlet opening has a plurality of inlet openings,wherein a first inlet opening of a first branch of the plurality ofbranches is disposed in a bottom surface of the anvil, and wherein asecond inlet opening of a second branch of the plurality of branches isdisposed in a side surface of the anvil.
 10. The anvil as set forth inclaim 1, wherein the curved passage has a plurality of branches, and theinlet opening has a plurality of inlet openings.
 11. The anvil as setforth in claim 1, wherein the anvil body includes a top surface, abottom surface, and a side surface between the top surface and thebottom surface, the side surface having at least three side surfaceportions and at least three corner portions, each corner portion of theat least three corner portions being disposed between respective pairsof side surface portions of the at least three side surface portions, atleast one corner portion of the at least three corner portionscomprising a surface that extends radially outward from a central axisof the anvil relative to extensions of a respective pair of side surfaceportions of the at least three side surface portions, the central axisextending between the top surface and the bottom surface.
 12. The anvilas set forth in claim 1, wherein the anvil body includes a top surface,a bottom surface, and a side surface between the top surface and thebottom surface, wherein the outlet opening is disposed in at least oneof the side surface and the top surface and the inlet opening isdisposed in at least one of the bottom surface and the side surface. 13.A method for making an anvil for a cutting tool according to claim 16,the method comprising: forming an anvil body having a curved passagethat extends from an inlet opening in the anvil body to an outletopening in the anvil body.
 14. The method as set forth in claim 13,comprising forming the anvil body via an additive manufacturing process.15. (canceled)
 16. A cutting tool comprising: a toolholder, thetoolholder having a recess; an anvil mounted in the recess, wherein theanvil includes an anvil body; and a cutting insert mounted in the recesson top of the anvil, the anvil having a top surface, a bottom surface, acentral axis extending between the top surface and the bottom surface,and a side surface disposed between the top surface and the bottomsurface, the side surface having at least three side surface portionsand at least three corner portions, each corner portion of the at leastthree corner portions being disposed between a respective pair of sidesurface portions of the at least three side surface portions, wherein acurved passage extends from an inlet opening in the anvil body to anoutlet opening in the anvil body, wherein at least one corner portion ofthe at least three corner portions includes a surface extending radiallyoutward from the central axis of the anvil relative to extensions of therespective pair of side surface portions of the at least three sidesurface portions, such that a limited portion of the top surface of theanvil extends past a bottom surface of the cutting insert to define anexposed area and wherein the outlet opening is arranged in the exposedarea to direct fluid toward the cutting edge.
 17. The cutting tool asset forth in claim 16, wherein the curved passage extends from the inletopening in the bottom surface.
 18. The cutting tool as set forth inclaim 16, wherein the curved passage extends from the inlet opening inthe side surface.
 19. The cutting tool as set forth in claim 16, whereinthe curved passage extends to the outlet opening in the top surface. 20.The cutting tool as set forth in claim 16, wherein the curved passageextends to the outlet opening in the side surface.
 21. The cutting toolas set forth in claim 16, wherein the anvil body includes a centralhole, the curved passage having a plurality of branches, and the inletopening having a plurality of inlet openings, wherein a first inletopening of a first branch of the plurality of branches is disposed on afirst side of the central hole, and wherein a second inlet opening of asecond branch of the plurality of branches is disposed on a second sideof the central hole opposite from the first branch.
 22. The cutting toolas set forth in claim 16, wherein the curved passage has a plurality ofbranches, and the inlet opening has a plurality of inlet openings,wherein a first inlet opening of a first branch of the plurality ofbranches is disposed in a first side surface of the anvil, and wherein asecond inlet opening of a second branch of the plurality of branches isdisposed in a second side surface of the anvil opposite from the firstside surface.
 23. The cutting tool as set forth in claim 16, wherein thecurved passage has a plurality of branches, and the inlet opening has aplurality of inlet openings, wherein a first inlet opening of a firstbranch of the plurality of branches is disposed in a bottom surface ofthe anvil, and wherein a second inlet opening of a second branch of theplurality of branches is disposed in a side surface of the anvil. 24.The cutting tool as set forth in claim 16, wherein the curved passagehas a plurality of branches, and the inlet opening has a plurality ofinlet openings.